PSM/RMP Modernization Programs in California 2016 Developments & Correlation to Evolution at the Federal Level (GCPS‐2017 – Paper 479475) Steven T. Maher Aleksandar Metulev Cho Nai Cheung Michael A. Vigliarolo Download Presentation & Handout – www.SEMS1.com/GCPS/2017.htm
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PSM/RMP Modernization Programsin California
2016 Developments & Correlationto Evolution at the Federal Level
(GCPS‐2017 – Paper 479475)
Steven T. MaherAleksandar MetulevCho Nai Cheung
Michael A. VigliaroloDownload Presentation & Handout – www.SEMS1.com/GCPS/2017.htm
Steven T. Maher, PE CSPRisk Management Professionals
• 37-Year Engineer – 33 in Process Safety Consulting Specializing in Hazard Analysis and QRA
• Mechanical Engineering– BS – Duke University– MS – Carnegie-Mellon University
• Professional Engineer – Mechanical & Chemical Engineering
• CCPS Technical Steering Committee – mid-1980s• Past-President Southern CA Society for Risk Analysis• Landmark Efforts
– Platform Safety Shutdown System Effectiveness Study– Torrance Refinery Safety Advisor for MHF Conversion
• Paper & Book Publications – See www.RMPCorp.com
Aleksandar MetulevRisk Management Professionals
• Chemical Engineering / Materials Science & Engineering - University of California Irvine
• HAZOP / LOPA Study Facilitator– Onshore and Offshore Production Facilities – Petroleum Refineries– Ammonia Refrigeration– Chemical Manufacturing– Pharmaceuticals
• Dispersion Modeling• P&ID Development• CalARP / RMP / PSM Program Development• Auditing• Webinar / Presentation Speaker on PSM/RMP
Issues
PSM/RMP Modernization Programsin California
2016 Developments & Correlationto Evolution at the Federal Level
(GCPS‐2017 – Paper 479475)
Steven T. MaherAleksandar MetulevCho Nai Cheung
Michael A. VigliaroloDownload Presentation & Handout – www.SEMS1.com/GCPS/2017.htm
Key Topics• Current SMS Program Elements &
Overlap• Expansion/Modernization Initiatives
Overview – 2016 Developments• Key Elements of Regulatory
Expansion/Modernization Efforts• Status, Impact, &
Strategies• Questions?
Current Safety Management System (SMS) Program
Elements & Overlap
Evolution of SMS Guidelines & Regulations to Performance (Goal) –
Based Standards
Onshore Process Safety (USA)
Offshore Safety Management Systems (USA)
Offshore Safety Management Systems (UK)
Overlap of Key Current CA SMS Programs (Onshore Facilities)
PSM CalARP/RMP
EPHA
PSIPHA
OP
TRN
MI
MOC
PSSRII
EPR
HWPCON
Minimal
CA
Overview of SMS Program Expansion/Modernization
Initiatives – 2016 Developments
Key Modernization Activities(Onshore Facilities)
www.RMPCorp.com/SMS_Regulatory_Updates/
EPA
IRTF
CCC & CoR
CalOES/CalEPA
CSB
OSHA Cal/OSHACalOES: California Office of Emergency Services; Cal/OSHA: California Occupational Safety & Health Administration; CSB: Chemical Safety Board; EPA: United States Environmental Protection Agency; IRTF: Interagency Refinery Task Force; OSHA: U.S. Occupational Safety & Health Administration; CalEPA: California Environmental Protection Agency; CCC: Contra Costa County; CoR: City of Richmond
Recent US SMS Regulatory Activities (Onshore Facilities)
EPA & OSHA
Chemical Safety Board & White House
California Agencies & Initiatives
CalARP-P4/CalPSM-RAffected Facilities
1 CalARP-P4/ CalPSM-R Facility
5 CalARP-P4/ CalPSM-R Facilities
3 CalARP-P4/ CalPSM-R Facilities
7 CalARP-P4/ CalPSM-R Facilities
Addressing Key Elements of CalARP, CalPSM-R, & RMP
Regulatory Expansion/Modernization Efforts
(with Implementation Tips)
Types of Changes
Facility/Program
Applicability
ScheduleElements
Current (2016) PSM Elements
PSM
EPPSI
PHA
OP
TRN
CON
PSSRMI
HWP
MOC
II
EP&R
CA
• Employee Participation• Process Safety Information• Process Hazard Analysis• Operating Procedures• Training• Contractors• Pre-Startup Safety Review• Mechanical Integrity• Hot Work Permit• Management of Change• Incident Investigation• Emergency Planning &
Response• Compliance Audits (CA-IIPP)
Impact Categories
• The changes in CalARP-P4 and CalPSM-R are expected to have different implementation challenges:* minimal changes to regulation or minimal effort needed for compliance** moderate changes to regulation or moderate effort needed for compliance*** new element or significant effort needed for compliance
CalPSM-R Elements
PSM-R
PSMPPSI
PHA
OP
TRN
CON
PSSR
MI
DMRIST/
HCA/STAA
HWMOC
II-RCA
EP&R
EP
PSCA
HF
MOOC
CA
• Process Safety Information• Process Hazard Analysis• Operating Procedures• Training• Contractors• Pre-Startup Safety Review• Mechanical Integrity• Damage Mechanism Review• Hierarchy of Hazard Control
Analysis (IST/HCA/STAA)• Hot Work• Management of Change• Incident Investigation - RCA• Emergency Planning & Response• Employee Participation• Process Safety Culture Assessment• Human Factors• Management of Organizational
Change• Compliance Audits• PSM Program (PSMP0
Current Cal/OSHA, CalARP, & RMP InitiativesProgram Element CalPSM-R
(Draft)CalARP(P4-Draft)
EPA-RMP(P2/3-Jan17)
Process Safety Information (PSI) * 5189.1(d) 2762.1 68.65
Process Hazard Analysis (PHA) *Safeguard Protection Analysis (SPA) ** (CA-Only) 5189.1(e) 2762.2
2762.2.1 68.50/67
Operating Procedures (OP) ** 5189.1(f) 2762.3 68.69
Training (TRN) * 5189.1(g) 2762.4 68.71
Contractors (CON) * 5189.1(h) 2762.12 68.87Pre-Startup Safety Review (PSSR) * 5189.1(i) 2762.7 68.77
Mechanical Integrity (MI) *Damage Mechanism Review (DMR) *** (CA-Only)
5189.(j)5189.1(k)
2762.5 68.73
IST / HCA / STAA *** 5189.1(l) 2762.13 68.67
Hot Work (HW) * 5189.1(m) 2762.11 68.85
Management of Change (MOC) ** 5189.1(n) 2762.6 68.75
Incident Inv. – Root Cause Analysis (II-RCA) ** 5189.1(o) 2762.9 68.81
Emergency Planning and Response (EP&R) *** 5189.1(p) 2765.2/3 68.95/96
Employee Participation (EP) * 5189.1(q) 2762.10 68.83
Process Safety Culture Assessment (PSCA) *** 5189.1(r) 2762.14 ---
Human Factors (HF) *** 5189.1(s) 2762.15 ---
Management of Organizational Change (MOOC) *** 5189.1(t) 2762.6 ---
Compliance Audits (CA) ** (Fed Rqmt. for 3rd Party) 5189.1(u) 2762.8 68.58/59/79/80
Process Safety Management Program (PSMP) ** 5189.1(v,w) 2762.16 ---
Status, Impact, & Strategies
Key Modernization Activities(Onshore Facilities)
www.RMPCorp.com/SMS_Regulatory_Updates/
EPA
IRTF
CCC & CoR
CalOES/CalEPA
CSB
OSHA Cal/OSHACalOES: California Office of Emergency Services; Cal/OSHA: California Occupational Safety & Health Administration; CSB: Chemical Safety Board; EPA: United States Environmental Protection Agency; IRTF: Interagency Refinery Task Force; OSHA: U.S. Occupational Safety & Health Administration; CalEPA: California Environmental Protection Agency; CCC: Contra Costa County; CoR: City of Richmond
Status and What to Expect
• Chemical Safety Board (CSB)– April 2013, October 2014, January 2015 – All 3
Investigation Reports Published– Investigation Completed, Recommendations Tracked
• U.S. EPA– 13Jan17 – Final Amendments to the RMP Rule
Published– 14Mar17 – EPA Issues Administrative Stay to Delay
Effective Date Until 17Jun17• Federal OSHA
– RFI Comments to be Processed– Promulgation of Updated PSM
Requirements and Timing Unclear– Timeline – “Years, not Months”– Interest Areas Handled by LoI
Status and What to Expect
• Contra Costa County & City of Richmond– June 2014 – Issued ISO 450-8 (“Risk Management”) &
Analogous CoR ISO– Current Initiative to Increase Involvement of Community
Oversight Group in Process Safety Culture Assessments• California Interagency Refinery Task Force (IRTF)
– Agency Meetings Continue– Additional Reports Not Planned
• Cal/OSHA CalPSM-R– 2015-2016 Updated §5189.1 Drafts Issued– 10Feb17 – Notice of Proposed Modifications to §5189.1– Final Regulation Promulgation – Estimated Summer 2017– Initially, 2 Separate PSM Regulations in California– No Planned Synchronization w/Federal PSM/RMP
Status and What to Expect
• CalEPA & CalOES CalARP– 01Jan15 – Promulgation of Minor Update to CalARP– 2015-2016 Updated Drafts Issued Aligning with §5189.1– 14Feb17 – Notice of Proposed Modifications to §5189.1– Final Regulation Promulgation – Estimated Summer 2017– Single CalARP Regulation with Additional
Requirements (Program 4) for“High Hazard Facilities” (NAICS 32411)
– Initially, Harmonization with §5189.1, but No Synchronization w/Federal PSM/RMP
Overlap of Key Current CA SMS Programs (Onshore Facilities)
PSM CalARP/RMP
EPHA
PSIPHA
OP
TRN
MI
MOC
PSSRII
EPR
HWPCON
Minimal
CA
Overlap of Post-2016 CA SMS Programs (Onshore Petroleum Refineries)
Fed-RMP – 2017? CalPSM-R (5189.1)
CalARP
EPPSI
PHA --- SPA
OP TRN
MI --- DMR
MOC --- MOOC
PSCAII-RCA
EPR
HWCON
HACA-3
IST/HCA/STAA
Schedule & Other “Minor”
Differences
HF
PSMP
PSSR
Schedule & Other “Minor”
DifferencesCA-1
EPR
EPR
What Should I be Doing Now?
• All California CalARP-Covered Facilities– Adherence to New 01Jan15 CalARP Requirements
• Contra Costa County & City of Richmond – 9 Facilities– Adherence to June 2014 CCC ISO 450-8 &
Analogous CoR ISO• California Petroleum Refineries
– 2016 did not see significant changes in the substance of the upcoming CalARP-P4/CalPSM-R requirements
– Implementation planning is important– Some elements (e.g., IST/HCA/STAA) are
significantly more cost-effective in the design-phase, or at the earliest possible opportunity
What Should I be Doing Now?
• U.S. PSM/RMP-Covered Petroleum Processing Facilities– Awareness of CalPSM-R for Best Practices for
“High Hazard Facilities”• All – Closely Monitor Regulatory Changes• Potential for:
– Later expansion to other highly-hazardous facilities in California
– Later expansion to non-Californiapetroleum refineries & others
– Inference to new requirementsas best practices
– General Duty Clause Correlation -SB 612 clarifies Owner/Operatorresponsibilities
Resources for Handling Evolving Requirements
• HAZOP/LOPA Facilitation Webinar Series (Module 10) – Effective approaches to handling CSB recommendations and PSM and CalARP changes
– DMR– SPA– Inherently Safer Technology/Design (i.e., IST/HCA/STAA)
• 2015 Global Congress on Process Safety – Papers– Maher, Nour, Schultz, “Effectively Addressing New PSM/RMP Damage Mechanism
Review Requirements with an Integrated PHA (iPHA)”
• 2017 Global Congress on Process Safety – Papers– Maher, Metulev, Cheung, Vigliarolo, “PSM/RMP Modernization Programs in California
(2016 Developments and Correlation to Evolution at the Federal Level)”• Webinars – Updates on the PSM/RMP Regulatory Modernization Programs
– 19Aug14 – 25Sep14– 22Jan15 – 09Apr15– 25Jun15 – 30Jul15– 27Aug15 – 28Jun16 – 29Oct15 – Regional Seminar – Simulcast as Webinar
• Webinar – DMR and the Integrated PHA (iPHA) Approach – 26Mar15 & 27Aug15 (w/simplifications)
• Links are provided on www.RMPCorp.com/SMS_Regulatory_Updates/
Summary & Conclusions
• Agencies have taken a fresh look at SMS Programs
• California and Refineries have biggest changes• Potential for:
– Expansion– Link to General Duty Clause & Best Practices
• Initial promulgation harmonizesCalARP & CalPSM-R
• No current plan to synchronize California and federal requirements
• There are “easy“ steps to take nowto infuse some of the newrequirements into yourPSM/RMP/CalARP activities
Summary & Conclusions
• Recommendation from a Key Regulator – Begin Applying “High-Value/Priority” Elements of CalPSM-R Now – Once promulgated, “schedule will be tight,” and if substantial progress has been made, selective ”grandfathering” may be allowed
• Tight schedules could result in a resource shortage• In addition, some elements (e.g., IST/HCA/STAA) are
significantly more cost-effective in the design-phase, or at the earliest possible opportunity
• Risk Management & Process Safety Professionals should:– Carefully monitor modernization programs– Focus on charting the course for the long-term success of your
facility’s programs– Develop a strategy for effective implementation
Steven T. Maher, PE [email protected]
Aleksandar [email protected]
Cho Nai [email protected]
Michael A. [email protected]
Questions?
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